F14 MULTIVALVE FUEL PUMP SERVICE MANUAL · 2016-03-22 · qty 1 2 1 1 1 2 f14 multivalve fuel pump...
Transcript of F14 MULTIVALVE FUEL PUMP SERVICE MANUAL · 2016-03-22 · qty 1 2 1 1 1 2 f14 multivalve fuel pump...
P11X4-9202-AA
Revision: A - Dated 10/18/11
Replaces: None
F14 MULTIVALVE FUEL PUMP
SERVICE MANUAL
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F14 MULTIVALVE FUEL PUMP
SERVICE MANUAL
HARDWARE CONTENTS
P13X4-4105-AA - PROPANE OPTIMIZATION KIT - EMERGENCY VEHICLES
COMPONENT
A - ROCKER SWITCH
B - 16 GA. GREEN/BLACK WIRE W/SPADE CONNECTOR
C - 1/4" CORRUGATE
D - CUT-OUT TEMPLATE FOR PADDLE SWITCH
E - ROCKER SWITCH BRACKET
F - BRACKET SCREWS
TOOLS REQUIRED
3mm ALLEN WRENCH
4mm ALLEN WRENCH
4mm ALLEN WRENCH SOCKET
8mm OPEN END WRENCH
13mm OPEN END WRENCH
TORQUE WRENCH (5 Nm CAPABILITY)
PHILLIPS HEAD SCREWDRIVER
ADJUSTABLE WRENCH OR CHANNEL LOCKS
10w30 MOTOR OIL (O-RING LUBRICANT)
LEAK DETECTION SOLUTION (SOAP & WATER)
INTRODUCTION
SAFETY WARNING
READ BEFORE STARTING SERVICING OF THE ICOM JTG SYSTEM.
ENSURE THAT ALL PERSONNEL IN THE IMMEDIATE AREA ARE AWARE OF THESE REMINDERS.
PROPANE IS A NONTOXIC, NONPOISONOUS GAS THAT IS EXTREMELY FLAMMABLE. IF SOMETHING IGNITES IT, YOU COULD BE
BADLY BURNED. KEEP SPARKS, OPEN FLAMES AND SMOKING MATERIAL AWAY FROM PROPANE.
LIQUID PROPANE IS EXTREMELY COLD (-40° F) AND CAUSE SERIOUS BURNS WHEN CONTACTING YOUR SKIN OR EYES. PREVENT
CONTACT WHEN HANDLING LPG BY WEARING APPROVED PROTECTIVE GLOVES AND EYE PROTECTION.
PROPANE IS STORED UNDER PRESSURE. THE FUEL SYSTEM OPERATES AT PRESSURES OF UP TO 312 PSI. A SUDDEN RELEASE
OF PROPANE CAN CAUSE SERIOUS INJURIES.
THESE INSTRUCTIONS ARE INTENDED FOR TECHNICIANS WHO ARE CERTIFIED BY ALL AGENCIES THAT GOVERN PROPANE INSTALLATIONS
AND THE TRANSPORTATION OF PROPANE. THE NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) PUBLISHES A CODE BOOK OF RULES
(NFPA 58) THAT APPLY TO THE STORAGE, HANDLING, TRANSPORTATION AND USE OF LIQUEFIED PETROLEUM GAS (LPG). LOCAL
PROPANE SUPPLIERS SUCH AS FERRELGAS AND AMERIGAS, AS WELL AS SOME AGENGIES SUCH AS THE TEXAS RAILROAD COMMISION
AND PERC (PROPANE EDUCATION & RESEARCH COUNCIL) OFFER INFORMATIVE COURSES TO HELP PREVENT SEVERE INJURY OR DEATH
TO YOU OR SOMEONE ELSE IF YOU DON'T FULLY UNDERSTAND LPG AND ITS PROPERTIES.
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40)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
3mm ALLEN WRENCH
ADJUSTABLE WRENCH
PART NUMBER DESCRIPTION TORQUE TOOLS
CAREFULLY REMOVE COLLAR COVER AND SET ASIDE
WRENCH, REMOVE THE NUT FROM THE TANK RELIEF PORT
AND SET ASIDE (IF EQUIPPED WITH PRV TUBE)
USING A PAIR OF CHANNEL LOCKS OR AN ADJUSTABLE
USING A 3mm ALLEN WRENCH, REMOVE (3) SCREWS IN
COLLAR COVER AND SET ASIDE
LOCATE MANUAL SUPPLY SHUT-OFF VALVE ON MULTIVALVE
COLLAR COVER; ROTATE KNOB 'CLOCKWISE' UNTIL IT STOPS
TO FULLY CLOSE SUPPLY VALVE
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
10
20
30
40
50)
60)
70)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
PART NUMBER DESCRIPTION TORQUE TOOLS
LOCATE AND GRASP THE ELECTROVALVE SUPPLY SOLENOID
WIRE HARNESS LEAD (RED & BROWN WIRES); CAREFULLY
DISCONNECT THE CONNECTOR FROM THE SOLENOID
LOCATE AND GRASP THE LPG FUEL PUMP WIRE HARNESS
LEADS (RED & BLACK WIRES); CAREFULLY DISCONNECT
THE CONNECTORS
LOCATE AND GRASP THE FUEL SUPPLY / COMMUTATOR
WIRE HARNESS LEADS; CAREFULLY DISCONNECT THE
CONNECTORS
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
50
60
70
80)
90)
100)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
13mm OPEN END WRENCH
4mm ALLEN WRENCH
8mm OPEN END WRENCH
PART NUMBER DESCRIPTION TORQUE TOOLS
LOCATE (5) SOCKET HEAD SCREWS THAT SECURE THE
FUEL PUMP HOUSING TO THE MULTIVALVE; USING A 4mm
ALLEN WRENCH, REMOVE THE (5) SCREWS AND SET ASIDE
LOCATE FUEL PUMP RETURN LINE ATTACHED TO THE
FUEL PUMP HOUSING; USING AN 8mm WRENCH, CAREFULLY
LOOSEN THE FITTING AND REMOVE THE LINE FROM THE
HOUSING
LOCATE FUEL SUPPLY LINE ATTACHED TO THE FUEL PUMP
HOUSING; USING A 13mm WRENCH, CAREFULLY LOOSEN
THE FITTING AND REMOVE THE LINE FROM THE HOUSING
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
80
90
100
110)
120)
130)
140)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
PHILLIPS SCREWDRIVER
PART NUMBER DESCRIPTION TORQUE TOOLS
USING A PHILLIPS HEAD SCREWDRIVER, REMOVE THE (2)
FUEL PUMP ATTACHMENT SCREWS AND SET ASIDE
LEADS
ROTATE FUEL PUMP COUNTER CLOCKWISE TO EXPOSE
THE (2) FUEL PUMP ATTACHMENT SCREWS
CAREFULLY REMOVE THE FUEL PUMP HOUSING AND FUEL
PUMP ASSEMBLY FROM THE MULTIVALVE
LOCATE AND DISCONNECT THE FUEL PUMP WIRE HARNESS
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
110
120
130
140
150)
160)
170)
180)
190)
200)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
P11X4-6900-AA FUEL PUMP SERVICE KIT 10w30 MOTOR OIL
PART NUMBER DESCRIPTION TORQUE TOOLS
OBTAIN FUEL PUMP FROM FUEL PUMP SERVICE KIT (A)
FULLY LUBRICATE O-RING ON FUEL PUMP SUPPLY HOSE
FITTING
USING A FLAT TIP SCREWDRIVER, ALIGN AND SEAT O-RING
ONTO THE FUEL PUMP HOUSING (DO NOT ROLL
O-RING ONTO FUEL PUMP HOUSING AS DAMAGE TO THE O-RING
MAY OCCUR)
OBTAIN O-RING FROM FUEL PUMP SERVICE KIT (A)
FULLY LUBRICATE O-RING WITH 10W30 MOTOR OIL
CAREFULLY REMOVE THE ORIGINAL O-RING FROM THE
FUEL PUMP HOUSING AND DISCARD
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
150
A
160
190
180
200
210)
220)
230)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
PHILLIPS SCREWDRIVER
PART NUMBER DESCRIPTION TORQUE TOOLS
OBTAIN (2) SCREWS REMOVED IN STEP 140; ALIGN HOLES IN
MOUNTING CLIP TO HOLES IN FUEL PUMP HOUSING; INSERT
SCREWS THROUGH MOUNTING CLIP HOLES AND
HAND TIGHTEN INTO FUEL PUMP HOUSING
CAREFULLY ALIGN AND SEAT SUPPLY HOSE FITTING ON
FUEL PUMP INTO FUEL PUMP HOUSING
POSITION FUEL PUMP TO HOUSING; LOCATE MOUNTING
CLIP ATTACHED TO FUEL PUMP SUPPLY HOSE FITTING
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
210
220
230
230)
240)
250)
260)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
PART NUMBER DESCRIPTION TORQUE TOOLS
CONNECTORS ARE FULLY SEATED)
LOCATE AND GRASP BLACK WIRE WITH SPADE CONNECTOR
ATTACHED TO THE FUEL PUMP
ALIGN AND SEAT SPADE CONNECTOR INTO FEMALE
CONNECTOR (SLIGHTLY PUSH/PULL CONNECTORS TO VERIFY
LOCATE AND GRASP BROWN WIRE WITH FEMALE
CONNECTOR ATTACHED TO THE FUEL PUMP HOUSING;
ALIGN AND SEAT SPADE CONNECTOR INTO FEMALE
CONNECTOR (SLIGHTLY PUSH/PULL CONNECTORS TO VERIFY
CONNECTORS ARE FULLY SEATED)
LOCATE AND GRASP RED WIRE WITH SPADE CONNECTOR
ATTACHED TO THE FUEL PUMP HOUSING: LOCATE AND GRASP
RED WIRE WITH BLACK FEMALE CONNECTOR ATTACHED
TO FUEL PUMP
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
230 240
250 260
270)
280)
290)
300)
310)
320)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
4mm ALLEN SOCKET
TORQUE WRENCH5.5Nm +/- .50
PART NUMBER DESCRIPTION TORQUE TOOLS
USING A 4mm ALLEN WRENCH, INSTALL AND HANDSTART
HANDSTART (5) SCREWS INTO MULTIVALVE
TORQUE SCREWS DIAMETRICALLY TO 5.5 Nm +/- .50
ALIGN AND SEAT FUEL PUMP HOUSING INTO MULTIVALVE;
POSITION MOUNTING HOLES IN THE FUEL PUMP HOUSING
TO THE MOUNTING HOLES IN THE MULTIVALVE
OBTAIN (5) SOCKET HEAD SCREWS REMOVED IN STEP 100
POSITON FUEL PUMP TO LINE UP BELOW THE FUEL PUMP
HOUSING AS SHOWN
CAREFULLY INSERT FUEL PUMP INTO MULTIVALVE AS SHOWN
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
270
280
310 320 1
1
2
3
4
5
1
330)
340)
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PROCESS NUMBER
P11X4-9202-AA
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NAME
8mm OPEN END WRENCH
13mm OPEN END WRENCH
PART NUMBER DESCRIPTION TORQUE TOOLS
TIGHTEN THE FITTING INTO THE HOUSING
LOCATE FUEL PUMP RETURN LINE; HANDSTART FITTING ON
LINE INTO HOUSING; USING AN 8mm WRENCH, FULLY
LINE INTO HOUSING; USING AN 13mm WRENCH, FULLY
TIGHTEN THE FITTING INTO THE HOUSING
LOCATE FUEL PUMP SUPPLY LINE; HANDSTART FITTING ON
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
?
330
340
350)
360)
370)
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INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
LOCATE AND GRASP THE ELECTROVALVE SUPPLY SOLENOID
WIRE HARNESS LEAD (RED & BROWN WIRES); ALIGN AND
SEAT THE CONNECTOR INTO THE SOLENOID
(SLIGHTLY PUSH/PULL CONNECTOR TO VERIFY FULLY SEATED
INTO SOLENOID)
LOCATE AND GRASP THE LPG FUEL PUMP WIRE HARNESS
LEADS (RED & BLACK WIRES); ALIGN AND SEAT CONNECTORS
TOGETHER (SLIGHTLY PUSH/PULL CONNECTORS TO VERIFY
CONNECTORS ARE FULLY SEATED)
LOCATE AND GRASP THE FUEL SUPPLY / COMMUTATOR
WIRE HARNESS LEADS; ALIGN AND SEAT CONNECTORS
TOGETHER (SLIGHTLY PUSH/PULL CONNECTORS TO VERIFY
CONNECTORS ARE FULLY SEATED)
PART NUMBER DESCRIPTION TORQUE TOOLS
PROCESS NAME
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NUMBER
P11X4-9202-AA
?
350 SOLENOID
360
370
380)
390)
400)
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INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
LOCATE SUPPLY SHUT-OFF VALVE ON MULTIVALVE: FULLY
ROTATE KNOB 'COUNTER CLOCKWISE' TO OPEN SUPPLY
VALVE
USING A LEAK DETECTION SOLUTION (SOAP & WATER), SPRAY
ALONG THE BOTTOM EDGE OF THE FUEL PUMP HOUSING
AND AROUND THE SUPPLY AND RETURN LINES TO VERIFY
NO LEAKS ARE PRESENT; (IF A LEAK IS DETECTED, THE SUPPLY
SHUT-OFF VALVE MUST BE COMPLETELY CLOSED BEFORE A
REPAIR CAN BE STARTED, ROTATE THE KNOB 'CLOCKWISE'
UNTIL THE KNOB STOPS TURNING TO CLOSE THE VALVE)
IF NO LEAKS ARE PRESENT, USE AN AIR HOSE AND NOZZLE
TO REMOVE THE LEAK DETECTION SOLUTION FROM THE
AREAS INSPECTED; LEAVE THE SUPPLY VALVE IN THE OPEN
POSITION
PART NUMBER DESCRIPTION TORQUE TOOLS
PROCESS NAME
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NUMBER
P11X4-9202-AA
?
380
SUPPLY SHUT-OFF VALVE
390
410)
420)
430)
440)
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PAGE12 OF 13
INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
CAREFULLY INSERT THE WIRE HARNESS LEADS BACK INTO
THE MULTIVALVE COLLAR AS SHOWN
OBTAIN THE COLLAR COVER REMOVED IN STEP 40; LOCATE
PRV TUBE (IF EQUIPPED) ON MULTIVALVE; ALIGN AND INSERT
PRV TUBE INTO LARGE OPENING ON MULTIVALVE COLLAR
LOCATE THE AUXILIARY SHUT-OFF KNOB ON THE COVER;
ALIGN AND SEAT THE AUXILIARY KNOB SHAFT ONTO
THE SHUT-OFF KNOB ON THE MULTIVALVE
ALIGN AND SEAT COLLAR COVER ONTO COLLAR
PART NUMBER DESCRIPTION TORQUE TOOLS
PROCESS NAME
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NUMBER
P11X4-9202-AA
?
410
420
430
440)
450)
460)
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INSPECTION ITEM NUMBER
TORQUE OPERATION
CRITICAL PROCESS
ALIGN AND SEAT COLLAR COVER ONTO COLLAR
IF EQUIPPED WITH PRV TUBE, OBTAIN NUT REMOVED IN
STEP 30; HANDSTART NUT ONTO TUBE; USING A PAIR OF
CHANNEL LOCKS OR AN ADJUSTABLE WRENCH, TIGHTEN
THE NUT SECURELY ONTO THE LID
OBTAIN (3) COLLAR COVER SCREWS REMOVED IN STEP 20;
INSERT SCREWS INTO HOLES IN LID; USING A 3mm ALLEN
WRENCH, HAND TIGHTEN SCREWS INTO MULTIVALVE
PART NUMBER DESCRIPTION TORQUE TOOLS
3mm ALLEN WRENCH
PROCESS NAME
MULTIVALVE FUEL PUMP REPLACEMENT
INSTRUCTIONSA
PROCESS NUMBER
P11X4-9202-AA
?
440
450
PRV TUBE
460